Printing utilizing a virtual mask

ABSTRACT

A method and apparatus for printing on an article are disclosed. An embodiment of a method may include the generation of a virtual mask that can designate areas for printing and/or designate areas to exclude from printing. A method may include utilization of the virtual mask during either 2D or 3D printing such that a print design is printed in areas designated for printing by the virtual mask.

BACKGROUND

The present embodiments relate generally to two-dimensional printing andthree-dimensional printing systems and methods.

Three-dimensional printing systems and methods may be associated withvarious technologies including fused deposition modeling (FDM), electronbeam freeform fabrication (EBF), and selective laser sintering (SLS), aswell as other kinds of three-dimensional printing technologies.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of an embodiment of components of athree-dimensional printing system as well as several articles that maybe used with the three-dimensional printing system;

FIG. 2 is a schematic view of an embodiment of a printing device and anarticle;

FIG. 3 is a flow diagram outlining the steps of an embodiment of theprinting process;

FIG. 4 is an isometric view of an embodiment of a portion of a sensorsystem, a portion of a computing system, and an article;

FIG. 5 is a isometric view of an embodiment of an article and a digitalrepresentation of the article;

FIG. 6 is an embodiment of a matrix providing information about aportion of the digital representation of FIG. 5;

FIG. 7 is an isometric view of an embodiment of an article and a portionof a printing device, a processed image, and a print design;

FIG. 8 is an isometric view of an embodiment of an article and a portionof a printing device;

FIG. 9 is an isometric view of an embodiment of an article and a portionof a printing device;

FIG. 10 is an isometric view of an embodiment of an article and aportion of a printing device;

FIG. 11 is an isometric view of an embodiment of a textile;

FIG. 12 is an embodiment of a digital representation of the textile ofFIG. 11;

FIG. 13 is a schematic view of an embodiment of a print design;

FIG. 14 is an isometric view an embodiment of a textile;

FIG. 15 is an isometric view an embodiment of a textile;

FIG. 16 is an isometric view of an embodiment of an article and aportion of a printing device, a processed image, and a print design;

FIG. 17 is an isometric view of an embodiment of an article and aportion of a printing device;

FIG. 18 is a flow diagram outlining the steps of an embodiment of theprinting process; and

FIG. 19 is a flow diagram outlining the steps of an embodiment of theprinting process.

DETAILED DESCRIPTION

Embodiments can include provisions to facilitate the printing of variousdesigns, patterns, and structures on a surface. In one embodiment, thepresent disclosure is directed to a method of printing on an article,the method comprising: obtaining data regarding the article using asensor system, forming a digitized image of the article, where thedigitized image comprises a plurality of pixels, and where the pluralityof pixels includes a first pixel and the first pixel represents aspecific area of the article. Furthermore, the method includes the stepof classifying the first pixel as belonging to a first category or asecond category; discharging a print material on the article using aprinting system if the first pixel belongs to the first category; andpreventing the specific area of the article represented by the firstpixel from receiving the print material if the first pixel belongs tothe second category.

In another embodiment, the present disclosure is directed to a method ofprinting on an object using a virtual mask, the method comprising:aligning the object within a printing system using a sensor system,obtaining data regarding the object using at least one image capturedevice, and registering the image to form a virtual representation ofthe object. Furthermore, the method comprises generating a virtual mask,where the virtual mask classifies different regions of the virtualrepresentation as belonging to either a print area or to an area whereprinting is prohibited, and then utilizing the virtual mask inconjunction with the printing system to exclude printing upon thedifferent portions of the object represented by regions classified inthe area where printing is prohibited.

In another embodiment, the present disclosure is directed to anapparatus for printing on an article, the apparatus comprising ahousing, where the housing includes a base disposed along the bottom ofthe housing, and where the housing is configured to receive the article.The apparatus further comprises a nozzle assembly configured todischarge a print material and a sensor system, where the sensor systemincludes an image capture device. The apparatus also includes acomputing system, where the computing system is configured to classifyareas of the article as a print area or an area prohibited fromprinting. The apparatus is configured to print a print design on theareas of the article classified as a print area, and the apparatus isalso configured to exclude printing of the print design on the areas ofthe article classified as an area that is prohibited from printing.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

FIG. 1 is a schematic view of an embodiment of a three-dimensionalprinting system 100, also referred to simply as printing system 100hereafter. FIG. 1 also illustrates several exemplary articles 130 thatmay be used with printing system 100. Referring to FIG. 1, printingsystem 100 may further comprise a printing device 102, a computingsystem 104, and a network 106.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal,” as used throughout this detaileddescription and in the claims, refers to a direction extending a lengthof a component. The term “longitudinal axis,” as used throughout thisdetailed description and in the claims, refers to an axis oriented in alongitudinal direction.

The term “lateral direction,” as used throughout this detaileddescription and in the claims, refers to a side-to-side directionextending a width of a component. For example, the lateral direction mayextend between a medial side and a lateral side of an article offootwear, with the lateral side of the article of footwear being thesurface that faces away from the other foot, and the medial side beingthe surface that faces toward the other foot. The term “lateral axis,”as used throughout this detailed description and in the claims, refersto an axis oriented in a lateral direction.

The term “horizontal,” as used throughout this detailed description andin the claims, refers to any direction substantially parallel with thelongitudinal direction, the lateral direction, and all directions inbetween. In cases where a component is placed on the ground, ahorizontal direction may be parallel with the ground.

The term “vertical,” as used throughout this detailed description and inthe claims, refers to a direction generally perpendicular to both thelateral and longitudinal directions, along a vertical axis. For example,in cases where a component is flat on a ground surface, the verticaldirection may extend from the ground surface upward.

In the embodiments shown in the figures, printing system 100 may beassociated with fused filament fabrication (FFF), also referred to asfused deposition modeling. In the embodiment shown in FIG. 1, printingdevice 102 of printing system 100 may use fused filament fabrication toproduce three-dimensional parts. An example of a printing device usingfused filament fabrication (FFF) is disclosed in U.S. Pat. No. 5,121,329to Crump, issued Jun. 9, 1992, and titled “Apparatus and Method forCreating Three-Dimensional Objects,” which application is hereinincorporated by reference and referred to hereafter as the “3D Objectsapplication.” Embodiments of the present disclosure can make use of anyof the systems, components, devices, and methods disclosed in the 3DObjects application. Printing device 102 may include a housing 110 thatsupports various systems, devices, components, or other provisions thatfacilitate the three-dimensional printing of objects (e.g., parts,components, or structures). Although the exemplary embodiment depicts aparticular rectangular box-like geometry for housing 110, otherembodiments could use any housing having any geometry and/or design. Theshape and size of housing 110 could be varied according to factorsincluding a desired footprint for the device, the size and shape ofparts that may be formed within printing device 102, as well as possiblyother factors. It will be understood that housing 110 could be open(e.g., provide a frame with large openings) or closed (e.g., with glassor panels of solid material and a door).

In some embodiments, printing device 102 may include provisions toretain or hold a printed object (or a component supporting the printedobject). In some embodiments, printing device 102 may include a table,platform, tray, or similar component to support, retain, and/or hold aprinted object or an object onto which printed material is applied. Inthe embodiment of FIG. 1, printing device 102 includes a tray 112. Insome embodiments, tray 112 may be fixed in place and act as a stablebase. In other embodiments, however, tray 112 could move. For example,in some cases, tray 112 may be configured to translate within housing110 in a horizontal direction (e.g., front-back and/or left right withrespect to housing 110) as well as a vertical direction (e.g., up-downwithin housing 110). Moreover, in some cases, tray 112 may be configuredto rotate and/or tilt about one or more axes associated with tray 112.Thus, it is contemplated that in at least some embodiments, tray 112 maybe moved into any desired relative configuration with a nozzle or printhead of printing device 102. In other embodiments, printing device 102may not include a tray 112. In some embodiments, tray 112 may be curved,irregularly shaped, or shaped to provide a customized platform uponwhich an article or object may be placed or secured. In someembodiments, printing device 102 may include an open space or cavityformed within tray 112.

In some embodiments, printing device 102 may include one or moresystems, devices, assemblies, or components for delivering a printedmaterial (or printed substance) to a target location. Target locationscould include the surface of tray 112, a surface or portion of apartially printed structure, and/or a surface or portion of anon-printed structure or component, such as a textile or other article.Provisions for delivering printed materials may include, for example,print heads and nozzles. In the embodiment of FIG. 1, printing device102 includes a nozzle assembly 116.

Nozzle assembly 116 may comprise one or more nozzles that deliver aprinted material to a target location. For purposes of clarity, theexemplary embodiment of FIG. 1 depicts a single nozzle 118 of nozzleassembly 116. However, in other embodiments, nozzle assembly 116 couldbe configured with any number of nozzles, which could be arranged in anarray or any particular configuration. In embodiments comprising two ormore nozzles, the nozzles could be configured to move together and/orindependently.

Nozzle 118 may be configured with a nozzle aperture (not shown) that canbe opened and/or closed to control the flow of material exiting fromnozzle 118. Specifically, the nozzle aperture may be in fluidcommunication with a nozzle channel that receives a supply of materialfrom a material source within printing device 102. Some examples ofmaterials that may be received or used are disclosed in U.S. PatentPublication Number 20170129176 to Sterman et al., published May 11,2017, and titled “Tack and Drag Printing Method,” which application isherein incorporated by reference in its entirety, and is hereinafterreferred to as the “Tack and Drag case.” Other examples include aqueousinks, dye-based inks, pigment-based inks, solvent inks, UV-curable inks,dye sublimation inks, and other print materials.

In some embodiments, a worm-drive may be used to push the filament intonozzle 118 at a specific rate (which may be varied to achieve a desiredvolumetric flow rate of material from nozzle 118). In other embodiments,a worm-drive is omitted. For example, the material may be pulled fromnozzle 118 using an actuating system. It will be understood that in somecases, the supply of material could be provided at a location nearnozzle 118 (e.g., in a portion of nozzle assembly 116), while in otherembodiments the supply of material could be located at some otherlocation of printing device 102 and fed via tubes, conduits, or otherprovisions, to nozzle assembly 116.

For purposes of this description, articles 130 may encompass a widevariety of objects, components, materials, and/or shapes that are flator include a three-dimensional geometry. Articles 130 may have portionsthat include curves, bumps, gaps, openings, and/or varying thickness,such as shown in articles 130 of FIG. 1. For example, an article mayhave regions or portions that are flat, smooth, level, or even, withrelatively little thickness. However, the same article may also includeuneven portions with surfaces that deviate from being flat for some orall of its length or area. In FIG. 1, articles 130 include an upper 134for an article of footwear, a knit structure 132, and a woven pattern136. In other embodiments, articles can comprise regular, geometriccurves such as those associated with circles, triangles, squares, andother geometric shapes, and/or they may also be irregular, for examplein articles shaped to accommodate or include a particular unevenconfiguration. For example articles 130 such as woven pattern 136 cancomprise one more tangible portions 138 and/or one or more apertures142. For purposes of this disclosure, a tangible portion may be amaterial portion that can receive a print material. Thus, tangibleportions 138 may be distinct from voids, spaces, gaps, etc. (forexample, apertures 142), which cannot receive a print material.Furthermore, it should be understood that the use of the term “aperture”herein represents any one or more of voids, spaces, gaps, recesses,and/or any other type of intangible portions, etc. In some embodiments,apertures 142 may be surrounded by or disposed adjacent to one or moretangible portions 138 of articles 130. The relationship between tangibleportions 138 and apertures 142 will be discussed in further detailbelow.

As will be described below, printing system 100 can include provisionsfor facilitating the alignment of a printed design or graphic onto anarticle. In some embodiments, it may be useful to provide a user with away of aligning an article or object with printing system 100 so as toensure a graphic is printed in the desired portion of the article. Inparticular, printing system 100 may include provisions for programmingthe orientation of an article with print device 102 in such a way as toaccommodate articles of various types, shapes, curves, and sizes. Thus,in some cases, printing system 100 may include provisions forpre-aligning the article (for example, with registration markers withinthe system). In some embodiments, the object may be aligned with tray112 and/or nozzle 118. In one embodiment, the object may beautomatically aligned within printing system 100 using techniques knownin the art.

In some embodiments, nozzle assembly 116 is associated with an actuatingsystem 114. Actuating system 114 may include various components,devices, and systems that facilitate the motion of nozzle assembly 116within housing 110. In particular, actuating system 114 may includeprovisions to move nozzle assembly 116 in any horizontal direction(including but not limited to a longitudinal direction 124 and a lateraldirection 126) and/or a vertical direction 122 to facilitate depositingor discharging a material so as to form a three-dimensional object or toprint along a three-dimensional or curved surface. To this end,embodiments of actuating system 114 may include one or more tracks,rails, and/or similar provisions to hold nozzle assembly 116 at variouspositions and/or orientations within housing 110. Embodiments may alsoinclude any kinds of motors, such as a stepper motor or a servo motor,to move nozzle assembly 116 along a track or rail, and/or to move one ormore tracks or rails relative to one another.

In some embodiments, an actuating system can be configured to move anozzle in one or more directions. In some embodiments, an actuatingsystem could move a nozzle in a single linear direction. In otherembodiments, an actuating system could move a nozzle in at least twoperpendicular directions. In still other embodiments, an actuatingsystem could move a nozzle in three perpendicular directions. Of course,while the exemplary embodiment depicts an actuating system capable ofmoving a nozzle through three independent x-y-z or Cartesian directions,other embodiments may be configured to move a nozzle in threeindependent directions associated with a non-Cartesian coordinate system(e.g., a spherical coordinate system or a cylindrical coordinatesystem). Still further, in other cases an actuating system could move anozzle through three different directions that may not be orthogonal(e.g., directions of an oblique coordinate system).

For purposes of this discussion, a print surface may be associated withthe surface where a nozzle is printing. For example, in cases wherenozzle 118 prints directly onto tray 112, the print surface isassociated with a surface of tray 112. In the embodiment of FIG. 1,print surface 148 is illustrated as the side of tray 112 that facesupward toward nozzle assembly 116. However, it should be noted that inother embodiments, print surface 148 may comprise the surface or side ofan article or object that is printed upon by nozzle 118, as shown inFIG. 2. Print surface 148 may be generally flat, or it may besubstantially curved and include contours. In one embodiment, printsurface 148 may be the side or surface of an object or article that isgenerally normal to first direction 160. Thus, print surface 148 mayrefer to the surface of an article that is attached to a printingmaterial such as a composite yarn or other material extruded orotherwise discharged or emitted from nozzle 118.

As shown in FIGS. 1 and 2, in different embodiments, printing system 100can include a sensor system 190. However, it should be understood thatin some embodiments, sensor system 190 may be independent from printingsystem 100. In other words, sensor system 190 may be a separate systemthat is used in conjunction with printing system 100. Sensor system 190may include various components, devices, and systems that facilitate thedetection of various features of articles 130 within housing 110.Although the exemplary embodiment depicts a particular camera componentrepresentation for sensor system 190, other embodiments could use anysystem having any geometry and/or design. The shape and size of thesensor system could vary according to factors including the type ofarticle being printed on, the size and shape of parts that may be formedwithin printing device 102, the arrangement of housing 110, as well aspossibly other factors.

In particular, sensor system 190 may include provisions to detect, map,or otherwise identify the presence of various surface types, such as theregions associated with apertures 142 and tangible portions 138. Sensorsystem 190 may further include an imaging device 192, (such as a cameraor other image capture device), which may move in any horizontaldirection and/or vertical direction 122 to facilitate the positionimaging device 192 within housing 110. The image capture device mayrecord images of the object and/or generates data representing theobject in some embodiments.

To this end, embodiments of sensor system 190 may include one or moretracks, rails, and/or similar provisions to reposition imaging device192 at various positions and/or orientations within housing 110. Inother words, sensor system 190 may include provisions for aligningarticles or objects such that appropriate recordings may be obtained.

Embodiments may also include any kinds of motors, such as a steppermotor or a servo motor that can move objects or imaging device 192 alonga track or rail, and/or to move one or more tracks or rails relative toone another. For purposes of clarity, imaging device 192 is shown inFIGS. 1-2 in isolation from any components that could be used to moveimaging device 192. In some embodiment, imaging device 192 or othercomponents of sensor system 190 may not be mobile and may instead bestationary within housing 110.

It should be noted that portions of sensor system 190 may be positionedin various locations within printing system 100 in order to provide thenecessary data capture and feature detection. For example, imagingdevice 192 could move from one location to another within printingsystem 100 in order to record data sufficient for generating a virtualrepresentation. In different embodiments, there may be multiple imagecapture devices, which may be used together to synthesize a compositeimage. In one embodiment, there may be a 2-5 image capture devices; inother embodiments, there may be more than five image capture devices,arranged throughout printing system 100. Thus, the data captured and/orgenerated by the image capture devices may be synthesized into acomposite image through an image registration process, where theresulting image can be made up of a first image portion, a second imageportion, a third image portion, etc. obtained from multiple sources.

For purposes of this disclosure, image registration is the process oftransforming sets of data into one coordinate system. Thus, in oneembodiment, image registration is the process of aligning two or moreimages of the same scene. The images or data may be obtained by onesource (e.g., a single camera taking images from various locations), orby multiple sources. In some embodiments, this process involvesdesignating one image as the reference (also called the reference imageor the fixed image), and applying geometric transformations to the otherimages so that they align with the reference. A geometric transformationcan map locations in one image to new locations in another image.

In some embodiments, components associated with sensor system 190 may bespecifically adapted to secure articles 130 in a fixed position ororientation. For example, some embodiments may include various kinds ofmounting devices, harnesses, temporary adhesives, or other provisionsthat may temporarily fix or hold the position of an article relative tohousing 110. Such provisions may help precisely orient a specificportion of an article towards nozzle 118 (and correspondingly towardsother components of printing device 102) or sensor system 190. Forexample, some embodiments could utilize a harness that fixes theorientation and position of an article over tray 112 so that imagingdevice can capture or scan data from along any desired portion of anarticle, such as upper 134 for an article of footwear. These provisionsmay also reduce the tendency of an article to move or jostle as theposition of tray 112 is adjusted, or nozzle 118 extrudes or releases aprint material onto articles 130.

Thus, in some embodiments, articles 130 may be scanned or otherwiseexamined or inspected in housing 110 before and/or during printing. Itshould be noted that actuating system 114 and sensor system 190 may beoperated simultaneously or independently during use of printing system100. In addition, actuating system 114 and sensor system 190 may beconnected in such a way so as to allow both to operate in conjunctionwith one another during printing. As discussed above, printing system100 can include provisions to control and/or receive information fromprinting device 102. These provisions can include computing system 104and network 106. Generally, the term “computing system” refers to thecomputing resources of a single computer, a portion of the computingresources of a single computer, and/or two or more computers incommunication with one another. Any of these resources can be operatedby one or more human users. Further, it should be understood that insome embodiments, computing system 104 may be independent from printingsystem 100. In other words, computing system 104 may be a separatesystem that is used in conjunction with printing system 100.

In some embodiments, computing system 104 may include one or moreservers. In some cases, a print server may be primarily responsible forcontrolling and/or communicating with printing device 102, while aseparate computer (e.g., desktop, laptop, or tablet) may facilitateinteractions with a user. Computing system 104 can also include one ormore storage devices including but not limited to magnetic, optical,magneto-optical, and/or memory, including volatile memory andnon-volatile memory.

In the exemplary embodiment of FIG. 1, computing system 104 may comprisea central processing device 185, a viewing interface 186 (e.g., amonitor or screen), input devices 187 (e.g., keyboard and mouse), andsoftware 180. While software 180 is represented in FIG. 1 as beingstored in computing system 104, it should be understood that in otherembodiments, software 180 may be accessed from other locations. In someembodiments, software 180 may be used for designing a computer-aideddesign (“CAD”) representation 189 of a printed structure. In at leastsome embodiments, the CAD representation 189 of a printed structure mayinclude not only information about the geometry of the structure, butalso information related to the materials required to print variousportions of the structure.

In different embodiments, software 180 may also be used to facilitateinteraction between computing system 104 and printing device 102,including sensor system 190. In some embodiments, for example, computingsystem 104 may include image edge detection software or another type ofclassification software, a processor configured with the software toreceive an image, and a process of decomposing and/or determining theareas of the image comprising tangible portions 138 relative tonon-tangible portions (e.g., apertures 142). For purposes of thisdescription, this operation or process may also be referred to as imagediscrimination. In one embodiment, printing system 100 may also generatea virtual mask to identify regions that will be excluded from printing.Virtual masks will be discussed further with respect to FIGS. 5-19.

According to one embodiment, imaging device 192 may provide a real-timevideo input source, including real-time video feed or other real-timedata. Alternatively, imaging device 192 may provide pre-recorded videodata. According to another embodiment, imaging device 192 may provideheat detection information, including infrared imaging data and/or otherheat detection information. One of ordinary skill in the art willreadily appreciate that other imaging data may be gathered and processedat various points during the image capture process. Thus, in differentembodiments, imaging device 192 may be utilized to capture informationfrom various objects. According to another embodiment, printing system100 may recognize any video source and any resolution that issufficiently clear to recognize the images. One skilled in the art willreadily appreciate that various types of imaging devices may beimplemented.

In other embodiments, computing system 104 can also include provisionsfor determining the edges of an object such as articles 130. In oneembodiment, an edge 194 is a portion of articles 130 where there is achange in the brightness of the image. For example, images taken byimaging device 192 may be processed such that tangible portions 138 areseparated or distinguished from the background in real-time analysis. Inanother embodiment, the processing may occur after the image iscaptured. Therefore, various edge detection or other technologies foridentifying different aspects of the image can be utilized. Someembodiments may make use of the features described in U.S. PatentPublication Number 2009/0192874 to Powles et al., published Jul. 30,2009 and titled “Systems and methods for targeted advertising,” thedisclosure of which is herein incorporated by reference in its entirety.Other embodiments may make use of the features described in U.S. Pat.No. 8,538,163 to Moesle et al., filed Sep. 29, 2010, and titled “Methodand system for detecting edges within an image,” the disclosure of whichis herein incorporated by reference in its entirety.

In some embodiments, computing system 104 may be in direct contact withprinting device 102 via network 106. Network 106 may include any wiredor wireless provisions that facilitate the exchange of informationbetween computing system 104 and printing device 102. In someembodiments, network 106 may further include various components such asnetwork interface controllers, repeaters, hubs, bridges, switches,routers, modems and firewalls. In some cases, network 106 may be awireless network that facilitates wireless communication between two ormore systems, devices, and/or components of printing system 100.Examples of wireless networks include, but are not limited to: wirelesspersonal area networks (including, for example, Bluetooth), wirelesslocal area networks (including networks utilizing the IEEE 802.11 WLANstandards), wireless mesh networks, and mobile device networks, as wellas other kinds of wireless networks. In other cases, network 106 couldbe a wired network including networks whose signals are facilitated bytwisted pair wires, coaxial cables, and optical fibers. In still othercases, a combination of wired and wireless networks and/or connectionscould be used.

It will be understood that for purposes of illustration, the components,devices and systems of printing system 100 are shown schematically inFIG. 1. It will therefore be appreciated that embodiments may includeadditional provisions not shown, including specific parts, components,and devices that facilitate the operation of actuating system 114,sensor system 190, computing system 104, network 106, and nozzleassembly 116. For example, actuating system 114 is shown schematicallyas including several tracks or rails, but the particular configurationand number of parts comprising actuating system 114 may vary from oneembodiment to another.

Printing system 100 may be operated as follows to form one or moreprinted images using a two-dimensional (2D) printing process in someembodiments. For purposes of this disclosure, 2D printing refers to therendering of 2D images on a substrate or other surface. In otherembodiments, printed structures may be formed using a three-dimensional(3D) printing, or additive, process.

Although some of the 3D printing embodiments shown in the figures depicta system using filament fused fabrication printing technologies, it willbe understood that still other embodiments could incorporate one or moredifferent 3D printing technologies. For example, printing system 100 mayuse a tack and drag print method, as described in the Tag and Drag case.Moreover, still other embodiments could incorporate a combination offilament fused fabrication and another type of 2D or 3D printingtechnique to achieve desired results for a particular printed structureor part. It should be understood that the techniques described hereinmay also utilize 2D printer systems (e.g., inkjets, etc.) and/or 3D(e.g., additive manufacturing) and processes.

In different embodiments, printing device 102 may use a variety ofdifferent materials for forming 2D images and/or 3D parts, including,but not limited to: inks, thermoplastics (e.g., polyactic acid andacrylonitrile butadiene styrene), high density polyethylene, eutecticmetals, rubber, clays (including metal clays), Room TemperatureVulcanizing silicone (RTV silicone), and porcelain, as well as possiblyother kinds of materials known in the art. In embodiments where two ormore different printed or extruded materials are used to form a part,any two or more of the materials disclosed above could be used.

In some cases, computing system 104 may be used to design a printpattern or a structure. This may be accomplished using some type of CADsoftware, or other kind of software. The design may then be transformedinto information that can be interpreted by printing device 102 (or arelated print server in communication with printing device 102). In somecases, the design may be converted to a 3D printable file, such as astereolithography file (STL file).

As discussed above, in some embodiments, printed structures may beprinted directly to one or more articles 130. The term “articles” isintended to include both articles of footwear (e.g., shoes) and articlesof apparel (e.g., shirts and pants), as well as various other objects.While the disclosed embodiments are described in the context oftextiles, the disclosed embodiments may further be equally applied toany article of apparel, clothing equipment, or other objects. Forexample, the disclosed embodiments may be applied to hats, caps, shirts,jerseys, jackets, socks, shorts, pants, undergarments, athletic supportgarments, gloves, wrist/arm bands, sleeves, headbands, any knitmaterial, any woven material, any nonwoven material, sports equipment,etc. Thus, as used throughout this disclosure, the term “article ofapparel” may refer to any apparel or clothing, including any article offootwear, as well as hats, caps, shirts, jerseys, jackets, socks,shorts, pants, undergarments, athletic support garments, gloves,wrist/arm bands, sleeves, headbands, any knit material, any wovenmaterial, any nonwoven material, etc. As used throughout thisdisclosure, the terms “article of apparel,” “apparel,” “article offootwear,” and “footwear” may also refer to a textile, a natural fabric,a synthetic fabric, a knit, a woven material, a nonwoven material, amesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.

Furthermore, objects made of other non-textile materials may alsoprovide print surface 148 in printing system 100. For example, articles130 may also include an article of footwear, a helmet, a glove, or otherarticles. Specifically, in some cases, printing device 102 may becapable of printing onto the surfaces of various materials such as atextile, a natural fabric, a synthetic fabric, a knit, a woven material,a nonwoven material, a mesh, a leather, a synthetic leather, a polymer,a rubber, and a foam, or any combination thereof. For example, thedisclosed methods may include printing a resin, acrylic, thermoplasticmaterial, or ink material onto a fabric, for example, a knit material,where the material is adhered or bonded to the fabric and where thematerial does not generally delaminate when flexed, rolled, worked, orsubjected to additional assembly processes or steps. As used throughoutthis disclosure, the term “fabric” may be used to refer generally tomaterials chosen from any textile, natural fabric, synthetic fabric,knit, woven material, nonwoven material, mesh, leather, syntheticleather, polymers, rubbers, foam, and combinations thereof.

In some embodiments, the horizontal or vertical position of articles 130may be adjusted using sensor system 190. Sensor system 190 may operatein conjunction with computing system 104 to provide greater automationto printing system 100.

As previously mentioned, nozzle 118 is configured to extrude ordischarge various materials. For example, as shown, nozzle 118 mayextrude a print material 202 such as a substantially elongatedcontinuous composite yarn, or nozzle 118 may extrude multiple elongatedcontinuous composite yarn segments. For example, in some embodiments,print material 202 may include a melt resistant material and/or a heatmoldable material, or another type of ink. As used herein, heat moldablematerial includes thermoplastic. In some embodiments, a composite yarnis at least partially formed of thermoplastic.

However, it should be noted that in other embodiments, print material202 may be discharged or otherwise emitted via nozzle 118 in the form ofdroplets. In some cases, droplets may comprise the print materials(e.g., inks) described earlier. One of ordinary skill in the art willrecognize that the form of the droplets may vary depending on the actualmaterial ejected or otherwise emitted from nozzle 118. In someembodiments, the droplets may thus be any viscosity liquid material, oreven a semi-solid material. Consistent with an embodiment, the dropletsmay be any desired material or phase of material suitable for use inprinting system 100.

The methods illustrated may be implemented on various devices, mayutilize various materials, and use different types of print surfaces.Accordingly, the exemplary methods illustrated in FIGS. 1-19 are forillustrative purposes only. In some embodiments, the printing can occurover articles 130 that have been previously manufactured or fabricated,or partially manufactured, and printing can occur post-manufacture. Thiscan allow customization of articles 130 to be processed more quickly, aswell as more cost-efficiently. Furthermore, printing system 100 canallow formation of designs that encompass multiple surfaces and curvesof article 130, including surfaces comprising varying materials, and canprovide more seamless design appearance.

As a general introduction to some of the embodiments described herein, aflow diagram is provided in FIG. 3. Before printing, an article may beplaced onto tray or may be otherwise secured in the housing in a firststep 310. The object may then be scanned or otherwise have data gatheredregarding the object by the sensor system in a second step 320. In athird step 330, the data may be used by the computing system to examinethe object and determine areas to exclude from printing. In a fourthstep 340, a virtual mask (described in further detail below) may begenerated by the computing system. Once the printing process isinitiated (by a user, for example), the printing device may begindepositing material onto the article. The printing system may employ thevirtual mask to limit printing to areas that have not been excluded bythe virtual mask in a fifth step 350. In a sixth step 360, printing iscompleted on the object.

Further detail on this process is provided below, with respect to FIGS.4-19. For purposes of convenience some components of printing system 100are not shown in the following figures. Thus, it should be understoodthat FIGS. 4-5, and 7-17 are for purposes of illustration only, and thecomponents described above with respect to FIGS. 1 and 2 may be includedor referred to in the following description while not illustrated in thefigures.

In FIG. 4, one embodiment of the image capture process 400 is depicted.In some embodiments, an initial image capture 489 of at least a portionof an article or object may be recorded by imaging device 192 of sensorsystem 190. As shown in FIG. 4, initial image capture 489 represents aportion of an article (not shown), where the article includes apertures142 and tangible portions 138. Processing may be performed usingcomputing system 104 in some embodiments, as depicted by CADrepresentation 189 shown on viewing interface 186. In one embodiment,initial image capture 489 may include obtaining data regarding theobject and forming a virtual representation of the article.

In one embodiment, computing system 104 may perform various edgedetection and discrimination processes, as described above. For example,computing system 104 may receive the image or data, apply an edgedetection process, and decompose the image or virtual representation ofthe object into one or more regions. In one embodiment, the multipleregions each represent different portions of the object.

The computing system 104 may generate a processed image 410 or virtualrepresentation, which in some embodiments may be used to generate avirtual mask (discussed further with reference to FIGS. 5 and 6). Theregions may be classified as either “print areas” 438 or “no-printareas” 442 in one embodiment. For purposes of this description, printareas 438 may represent portions of the object upon which printing is tobe permitted (i.e., a printable area), and no-print areas 442 representportions of the object upon which printing is to be excluded. In otherwords, no-print areas are areas prohibited from printing. It should beunderstood that in some cases, there may not be any print areas 438identified, and in other cases, there may not be any no-print areas 442identified. As illustrated in FIG. 4, each of no-print areas 438 inprocessed image 410 can correspond to each of apertures 142 in initialimage capture 489 in some embodiments. In other embodiments, each ofprint areas 438 can correspond to each of tangible portions 138. Inother words, the printing system as described herein may includeprovisions for detecting areas where printing may occur, and areas whereprinting should not occur, and adjust the output of nozzle 118 (notshown) accordingly.

It should be understood that the areas designated as no-print may bemanually entered by a user, or may be programmed or otherwise providedto computing system 104 such that the designation may occur in anautomated fashion. Furthermore, the discrimination process and/or thegeneration of a virtual mask may occur in real-time (i.e., duringprinting or after print material has been discharged) or it may begenerated prior to printing.

FIGS. 5 and 6 depict one embodiment of the operation of the imagediscrimination process. In FIG. 5, sensor system 190 (not shown) hascaptured a digitized image 550 of a portion of article 500. For purposesof this disclosure, digitization may refer to the process of convertingan image into a digital form that can be processed by a computingsystem. Thus, in some embodiments, sensor system 190 can capture animage of article 500 and divide the total picture area into rows andcolumns comprising a large number of relatively tiny subareas. In theembodiment of FIGS. 5 and 6, this digital organization of numeric datawill be referred to as pixels 520. Pixels 520 can contain the digitalnumeric red-green-blue (RGB) color data (numbers) of one portion of theimage's surface area. In other words, a row and column array of pixelsmay be created by computing system 104 in some embodiments. As eachpixel is generally stored as a color sampled from the frame area, pixelscan be utilized by printing system 100 during the image discriminationprocess. It should be understood that RGB color identification is onlyan example of one means of digitally processing and/or storing the imagedata, and other processes may be used as known by persons skilled in theart.

Therefore, in some embodiments, an image file can be created bycomputing system 104, including three color values for every RGB pixel,or location, in the image grid of rows and columns. The data is alsoorganized in the file in rows and columns. File formats may vary indifferent embodiments. Some examples include BMP, JPEG, GIF, PNG, TIFF,PICT, and other image file formats. The viewing software can then depicteach location along one of the rows and along one of the columns in thegrid of rows and columns. It should be understood that in someembodiments, the use of pixels implies the virtual construction of a“grid” of pixels that compose or comprise an image.

In FIG. 5, for purposes of illustration, an embodiment of a portion of arow of pixels 520 is identified, including a first pixel 502, a secondpixel 504, a third pixel 506, a fourth pixel 508, and a fifth pixel 510.First pixel 502, second pixel 504, and third pixel 506 are associatedwith tangible portions 138. Fourth pixel 508 and fifth pixel 510 areassociated with apertures 142. In some embodiment, each pixelcorresponds to or represents a unique or specific location, area, orportion of article 500. Thus, in one embodiment, first pixel 502 canrepresent a first area on article 500, and second pixel 504 canrepresent a second area on article 500, such that the first area and thesecond area are different.

In FIG. 6, a matrix is illustrated, listing the pixels identified inFIG. 5, each pixel's location in the digitized image, the color valueassigned to the pixel, as well as the resulting classification of thepixel to either a print area (yes) or a no-print area (no). It should beunderstood that the matrix including the pixel number, values of thelocation of each pixel, the color value, and the classification to aprint area or no-print area is provided as an example only, and thatvalues other than those included in FIG. 6 may be listed in the matrix.

As shown in FIG. 6, first pixel 502, second pixel 504, and third pixel506 have been designated or classified as print areas, and fourth pixel508 and fifth pixel 510 have been designated or classified as no-printareas. As a result of this classification, a virtual mask may begenerated by computing system 104. In one embodiment, the virtual maskmay be superimposed on the processed or digitized image or be otherwiseapplied to the original data regarding the object. For purposes of thisdisclosure, a virtual mask may be a simulated or digital mask, and maynot physically exist. The virtual mask can substantially “block”portions of an image in some embodiments. In one embodiment, the virtualmask can include a shape or outline that substantially corresponds tothe shape of the digitized image, while any regions identified andclassified to the no-print areas are filled with a type of limitingcontent, such as a uniform pre-selected color or other graphics. In someembodiments, the virtual mask may be automatically generated during theimage discrimination process. However, in other embodiments, the virtualmask may be superimposed on the digitized image by a user.

For example, the virtual mask may fill or otherwise superimpose on theregion of the no-print areas in the processed image a color or patternthat will be light absorbing color (e.g., black), or any otherspecialized pattern, such that the printing system interprets orotherwise is instructed to avoid printing in the no-print area,regardless of the print design. In one embodiment, the use of virtualmasks can avoid printing on regions of tray 112 (not shown) or othersurfaces that do not require printing. Printing resources can thus beconserved, printing may be more efficient, clean-up of print areas maybe minimized, print bleeding can be decreased, and/or image or printresults can be optimized in some embodiments.

FIGS. 7-10 illustrate an embodiment of the printing process thatincludes a virtual mask during 2D printing. In FIG. 7, an example of aprint design 700 is shown. Print design 700 can be programmed, selected,uploaded, or otherwise inputted into printing system 100 during theprinting process. As shown, print design 700 is a repeating pattern ofround dots 702. In other embodiments, print design 700 may include anydesign, including 2D and 3D designs.

In some embodiments, the image capture process as discussed may producea processed image 710 of a portion of an article 720. Processed image710 includes print areas 438 and aperture regions 442. Thus, in oneembodiment, processed image 710 may be used to form a virtual mask,which can be utilized by printing system 100 during printing to identifyareas on which to avoid printing. As shown in FIG. 7, nozzle 118 hasbegun to deposit print material 202 along print surface 148. Article 720includes apertures 142, and tangible portions 138. Printing system 100may overlay or otherwise make reference to the virtual mask generatedfrom processed image 710. In one embodiment, print surface 148 may be asurface of the substrate or material portions of article 720.

In FIG. 8, nozzle 118 has moved along one side of article 720, in agenerally longitudinal direction 124, depositing dots 702. As shown inFIG. 8, dots 702 are only deposited on print surface 148 that have beencharacterized as a print area (i.e., tangible portions 138). In otherwords, despite the inclusion of print design 700 shown in FIG. 7, whichincludes a continuous pattern of dots 702, printing of print design 700is limited to the areas identified by printing system 100 as a printsurface 148 or print area. This is further depicted in FIGS. 9 and 10.In FIG. 9, printing has occurred in both longitudinal direction 124 andlateral direction 126, across a majority of article 720. Printing onarticle 720 is being completed in FIG. 10. It can be seen that in bothFIGS. 9 and 10, printing has been limited to regions identified as printareas (i.e., associated with tangible portions 138). Thus, in oneembodiment, the areas of tray 112 associated with each of apertures 142remain unprinted upon.

FIGS. 11-15 depict another possible embodiment of the printing processas described herein. FIG. 11 is an embodiment of a textile 1100. Textile1100 includes six apertures 1142 that are surrounded or bounded bytangible portions 1138. Apertures 1142 include a first aperture 1102, asecond aperture 1104, a third aperture 1106, a fourth aperture 1108, afifth aperture 1110, and a sixth aperture 1112. As shown in FIG. 11,each aperture may have a different shape and/or size. For example, firstaperture 1102 is generally starburst shaped, second aperture 1104 isgenerally pentagonal shaped, third aperture 1106 is generally lighteningshaped, fourth aperture 1108 is generally star shaped, fifth aperture1110 is generally heart shaped, and sixth aperture 1112 is generallycircular shaped. Thus, apertures 1142 may include sharp edges and/orcurves, and a variety of geometries. In other embodiments, apertures1142 may be larger or smaller than those depicted, and include otherregular or irregular shapes.

FIG. 12 is an embodiment of a processed image 1200 representing textile1100 in FIG. 11. In FIG. 12, aperture regions 1242 and tangible regions1238 are shown. Aperture regions 1242 include a first aperture region1202, a second aperture region 1204, a third aperture region 1206, afourth aperture region 1208, a fifth aperture region 1210, and a sixthaperture region 1212. As shown in FIGS. 11 and 12, first aperture 1102in textile 1100 corresponds to first aperture region 1202 in processedimage 1200. Similarly, second aperture 1104 corresponds to secondaperture region 1204, third aperture 1106 corresponds to third apertureregion 1206, fourth aperture 1108 corresponds to fourth aperture region1208, fifth aperture 1110 corresponds to fifth aperture region 1210, andsixth aperture 1112 corresponds to sixth aperture region 1212. Thus,processed image 1200 may be a digital representation of specified areasof textile 1100 in some embodiments demarcating between print areas(associated with tangible regions 1238) and no-print areas (associatedwith aperture regions 1242).

In other words, when a print design is processed by printing system 100,the virtual mask generated (e.g., using processed image 1200) may beused to indicate or otherwise inform printing system which areas willnot be printed upon. Thus, using this process, regardless of the actualprint design employed, only the areas identified and targeted by theprinting system as print areas will receive the print material.

For example, in FIG. 13, a print design 1300 is shown. Print design 1300includes a series of unbroken or continuous curves 1310 extending acrossthe image. Print design 1300 includes curves 1310 of varying sizes, andcurves 1310 that extend across various portions of the design area. Inthe embodiment of FIG. 13, curves 1310 include a first curve 1302.

To provide a comparison, in one example of a printing system that doesnot employ a virtual mask as described, print design 1300 of FIG. 13 maybe printed on a surface without regard for the type of surface or forwhether there is substrate actually present in the targeted print area.For example, in FIG. 14, an embodiment of a first printed textile 1400is illustrated. Print design 1300 has been deposited on print surface148. Print surface 148 includes the entire region bordered by the edgesof first printed textile 1400, including the areas associated with bothtangible portions 1138 and apertures 1142. Thus, in the example of FIG.14, tray 112 may be a target for print material 202.

However, in embodiments that utilize a virtual mask, print design 1300of FIG. 13 may be deposited such that tray 112 is no longer classifiedas a print surface. For example, in FIG. 15, as the information from thevirtual mask is included in the printing process, specified areas havebeen blocked from printing. In other words, in some embodiments,apertures 1142 of a second printed textile 1500 are avoided or excluded,while tangible portions 1138 are printed upon. Thus, areas of tray 112associated with the no-print zones (e.g., apertures 1142) remain clearof print material 202, while tangible portions 1138, representing printsurface 148, include print material 202 generally matching thecorresponding sections of print design 1300 (shown in FIG. 13).

The use of the virtual mask may allow or otherwise permit printing tooccur more efficiently and decrease the overall cost (e.g., ink,clean-up, post-processing) of the printing process. Furthermore, thetechniques described herein can permit the application of a variety ofdesigns on a wide variety of articles, including articles with unevensurfaces, gaps, or other irregularities. For example, a desired printdesign need not be altered or adjusted to accommodate the type of printsurface prior to printing, because only the surfaces classified as printzones will receive the print material. Additionally, post-manufacturecustomization of articles may be easier, as well as quicker.

The embodiments described herein can also be directed to 3D printing.FIGS. 16 and 17 illustrate an embodiment of the printing process thatincludes a virtual mask during 3D printing. In FIG. 16, an example of aprint design 1600 is shown. Print design 1600 can be programmed,uploaded, or otherwise inputted into the printing system during theprinting process. As shown, print design 1600 is a repeating pattern ofcloud ornaments 1602. In other embodiments, print design 1600 mayinclude any design, including 2D and 3D designs.

In some embodiments, the image capture process as discussed may producea processed image 1610 of a portion of an article 1620. Processed image1610 includes print areas 438 and aperture regions 442. Thus, in oneembodiment, processed image 1610 may be used as a virtual mask, whichcan be utilized by printing system 100 during printing to identify areason which to avoid printing. As shown in FIG. 16, nozzle 118 has begun todeposit three-dimensional print material 202 along print surface 148. Inone embodiment, print surface 148 may comprise of the substrate ofarticle 1620. Article 1620 includes apertures 142, and tangible portions138. Printing system 100 may overlay or otherwise make reference to thevirtual mask generated from processed image 1610.

In FIG. 17, nozzle 118 has moved along multiple sides of article 1620,depositing cloud ornaments 1602. Printing has occurred in bothlongitudinal direction 124 and lateral direction 126, across a majorityof article 1620. As shown in FIG. 17, cloud ornaments 1602 are onlydeposited on tangible portions 138 that have been characterized as aprint area. In other words, despite application of print design 1600shown in FIG. 16, which includes a continuous pattern of cloud ornaments1602, printing of the structures of print design 1600 is limited to theareas identified by printing system 100 as a print surface 148. It canbe seen that in both FIGS. 16 and 17, printing has been limited toregions identified as print zones (i.e., associated with tangibleportions 138). Thus, in one embodiment, the areas of tray 112 associatedwith each of apertures 142 remain unprinted upon.

Referring back to the various printing embodiments depicted in FIGS.7-17, in some embodiments, it should be understood that print designsmay be utilized by printing system 100 in different ways. In oneembodiment, the print designs may be “mapped” to facilitate the virtualmasking process. For purposes of this disclosure, mapping refers to anoperation or process that associates each of the elements of a given setwith one or more elements of a second set.

In some embodiments, selected print design 700, print design 1300,and/or print design 1600 may be stored or represented by a plurality orregion of pixels (e.g., similar to the representation of digitized image550 by pixels 520 in FIG. 5 above). To provide one example of a mappingprocess, the selected print design may include a first sectionrepresented by a first set of pixels, and a second section representedby a second set of pixels. Similarly, the digitized image can alsoinclude two sets of pixels, for example, a third set of pixels and afourth set of pixels.

In some embodiments, each pixel in the first set of pixels from theprint design can be mapped (associated) with each pixel in the third setof pixels from the digitized image. Furthermore, each pixel in thesecond set of pixels from the print design can be mapped (associated)with each pixel in the fourth set of pixels from the digitized image.Thus, in one embodiment, the pixels representing the print design can belinked or correlated to the pixels representing the digitized image. Insome cases, this linkage can occur by determining the mappingrelationship between each of the sets of pixels, such that the grid ofpixels representing the digitized image and the grid of pixelsrepresenting the print design are matched and/or spatially correlated.

To determine the mapping between the digitized image and the printdesign, a bitmap or pixmap of the print design and/or digitized imagemay be generated. For purpose of this disclosure, a bitmap or pixmap isa type of memory organization or image file format used to store digitalimages, and may refer to the concept of a spatially mapped array ofpixels. The mapping process may also utilize raster images, whethersynthetic or photographic, in files or memory.

In one case, utilizing the masking methods described herein, the firstsection of the print design may then be printed onto the article whenthe third set of pixels are all classified in the “print areas”category, and the second section of the print design can be preventedfrom being printed onto the article (or areas associated with thearticle) when the fourth set of pixels are classified in the “no-printareas” category. In another case, the first section of the print designmay be prevented from being printed onto the article (or areasassociated with the article) when the third set of pixels are allclassified in the “no-print areas” category, and the second section ofthe print design can be printed onto the article when the fourth set ofpixels are classified in the “print areas” category.

One embodiment of the printing process as described herein is outlinedin the flow chart of FIG. 18. An object or article located within thehousing may be scanned or data regarding the article may be otherwiseobtained (for example, using the sensor system described above) in afirst step 1810. In a second step 1820, the scanned information may beused by the computing system to generate a digital (pixelated) image. Insome embodiments, each pixel may represent a specific area of thearticle. In a third step 1825, a pixel is selected for examination. In afourth step 1830, one pixel is examined and assigned or classified aseither a print area or print zone in a fifth step 1840, or as a no-printarea or print zone in a sixth step 1850. In other words, the pixel maybe classified in one of at least two categories, where the firstcategory is associated with allowing printing to occur, and where thesecond category is associated with the exclusion of any printing. Sixthstep 1850 may occur in conjunction with the software (e.g., edgedetection or classification) of the computing system in someembodiments. In a seventh step 1860, the printing system determines ifany pixels remain unexamined. If there is at least one additional pixelremaining, the process returns to third step 1825. If no pixels remain,a virtual mask is generated in an eighth step 1870. In a ninth step1880, printing is initiated which utilizes the virtual mask generated ineighth step 1870. The virtual mask may be superimposed on the digitalimage originally generated in second step 1820 in some embodiments. Theprint job is completed in a tenth step 1890, where the virtual mask canbe used to exclude some areas of the article from receiving printedmaterial.

As mentioned above, the processes described herein may occur inreal-time in some embodiments. For purposes of this description, areal-time virtual mask process may occur when one or more of the pixelsrepresenting the object are classified after printing has begun (i.e.,some of the print material has been discharged before all pixels havebeen classified). A general outline of an embodiment of a real-timevirtual mask printing process is provided in the flow diagram of FIG.19. It should be understood that there may be additional steps in otherembodiments, or the steps may differ from those listed in FIG. 19 insome embodiments.

Before printing, a print design may be selected in a first step 1910. Anobject or article located within the housing may then be scanned or dataregarding the article may be otherwise obtained (for example, using thesensor system described above) in a second step 1920. In a third step1930, the data may be used by the computing system to generate or rendera digital (pixelated) image. In some embodiments, each pixel mayrepresent a specific area of the article. In a fourth step 1935, a pixelis selected for examination. It should be understood that in someembodiments, the pixel selected is identified with an area of the objectthat will be printed on, allowing the system to perform and apply avirtual mask in substantially real-time. In a fifth step 1940, one pixelis examined and assigned or classified as either a print area or printzone in a sixth step 1950, or as a no-print area or no-print zone in aseventh step 1960. In other words, the pixel may be classified in one ofat least two categories, where the first category is associated withallowing printing to occur, and where the second category is associatedwith the exclusion of any printing. Seventh step 1960 may occur inconjunction with the software (e.g., edge detection or classification)of the computing system in some embodiments. If the pixel is designatedas a print area, print material may be deposited on the region of thearticle associated with the pixel in an eighth step 1970. Thus, printingmay occur in real-time in some embodiments, as the pixels that areclassified for printing receive the print material soon after thedesignation. Furthermore, if the pixel is designated as a no-print area,printing will be excluded from the region of the article associated withthe pixel in a ninth step 1980. In a tenth step 1990, printing systemdetermines if any pixels remain to be examined. If there is anadditional pixel, the process returns to fourth step 1935. If no pixelsremain, the print job is completed in an eleventh step 1992.

It should be understood that in other embodiments, the generation of avirtual mask may be based on data other than pixels. For example, thesoftware used may designate the various aspects or features of an objectusing other samples, representations, and/or data collected of theobject. It should further be understood that the steps listed in theflow charts of FIGS. 3, 18, and 19 are not intended to be comprehensiveand are provided as possible embodiments of the printing process. Inother words, the process may also incorporate any of the othertechniques described herein, as well as others practiced by thoseskilled in the art.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Although many possible combinations of features are shownin the accompanying figures and discussed in this detailed description,many other combinations of the disclosed features are possible. Anyfeature of any embodiment may be used in combination with or substitutedfor any other feature or element in any other embodiment unlessspecifically restricted. Therefore, it will be understood that any ofthe features shown and/or discussed in the present disclosure may beimplemented together in any suitable combination. Accordingly, theembodiments are not to be restricted except in light of the attachedclaims and their equivalents. Also, various modifications and changesmay be made within the scope of the attached claims.

What is claimed is:
 1. A method of selectively omitting a portion of aprint design based on detecting a feature of an article to print theprint design except the selectively omitted portion on the article, themethod comprising: disposing the article on a portion of a print system;forming a digitized image of the article based on data obtained from asensor system while the article is on the portion of the print system,wherein the digitized image comprises at least a first regionrepresenting at least a portion of the article; using a computingsystem, classifying first portions of the first region as belonging to afirst category and classifying second portions of the first region asbelonging to a second category corresponding to a detected feature ofthe article, the first and second portions being classified based on thedigitized image; discharging a print material on the article based onthe print design, using the printing system, on the at least a portionof the article represented by the first region if the first region isclassified in the first category; and preventing the discharge of printmaterial on the at least a portion of the article represented by thefirst region if the first region is classified in the second category;wherein the discharged print material on the article constitutes anincomplete form of the print design lacking print material at theselectively omitted portion of the print design corresponding to thedetected visible feature of the article.
 2. The method according toclaim 1, wherein the sensor system includes an image capture device thathelps to produce the digitized image.
 3. The method according to claim1, further comprising classifying each region of the digitized image asbelonging to the first category or the second category.
 4. The methodaccording to claim 1, further comprising: generating a virtual maskcomprised of all of the regions classified in the second category; andpreventing areas of the article represented by regions in the virtualmask from receiving the print material.
 5. The method according to claim1, wherein: the article comprises a plurality of tangible portions and aplurality of apertures; wherein the regions representing the pluralityof tangible portions are classified in the first category; and whereinthe regions representing the plurality of apertures are classified inthe second category.
 6. The method according to claim 4, furthercomprising: selecting a digitized print design that is a digitalrepresentation of the print design; applying the virtual mask to thedigitized print design so that at least some of the digitized printdesign is identified with the virtual mask; printing a first portion ofthe digitized print design onto the article; and preventing a secondportion of the digitized print design that is identified with thevirtual mask from being printed.
 7. The method according to claim 1,further comprising printing at least one three-dimensional structureonto the article.
 8. The method according to claim 1, further including:printing the print design on the article; and wherein the step ofclassifying further includes classifying at least one region after someof the print material has been discharged.
 9. The method according toclaim 1, wherein the first region of the digitized image comprises atleast one pixel.
 10. A method of printing on an object using a virtualmask, the method comprising: placing the object on a tray in a printingsystem; obtaining image data regarding the object while the object is onthe tray using at least one image capture device; forming a virtualrepresentation of the object based on the image data and demarcating thevirtual representation into one or more regions representing differentportions of the object; generating a virtual mask based using acomputing system, wherein the virtual mask classifies each region of thevirtual representation as belonging to either a first area whereprinting is permitted or a second area where printing is prohibited;selecting the print design; preventing the discharge of the printmaterial on the object based on the print design at portions of theobject that correspond to the first area to selectively omit portions ofthe print design; and discharging a print material on the object basedon the print design at portions of the object that correspond to thesecond area, wherein the discharged print material on the objectconstitutes an incomplete form of the print design lacking printmaterial at the selectively omitted portions of the print design thatcorrespond to the first area.
 11. The method according to claim 10,wherein the step of generating a virtual mask further includesclassifying at least one region after the print material has beendischarged.
 12. The method according to claim 10, wherein the objectincludes a plurality of apertures, and wherein the virtual maskclassifies regions representing the plurality of apertures as belongingto the second area.
 13. The method according to claim 12, wherein theobject has a three-dimensional geometry.
 14. The method according toclaim 13, further comprising classifying each of the regionsrepresenting the plurality of tangible portions as belonging to the areawhere printing is permitted.
 15. The method according to claim 13,further comprising classifying each of the regions representing theplurality of apertures as belonging to the area where printing isprohibited.
 16. The method according to claim 12, wherein the objectfurther includes a plurality of tangible portions and the virtual maskclassifies regions representing the plurality of tangible portions asbelonging to the first area.
 17. The method according to claim 10,further comprising aligning the object with the tray and a print nozzleusing a sensor system.